TECHNICAL FIELD
[0001] The present disclosure relates generally to storing and retrieving items in rack
based systems.
BACKGROUND
[0002] Warehousing and distribution facilities have grown in importance in the supply chain
in recent years. In such facilities, large warehouses are used to collect and store
many types of goods at a central location for shipment by truck to one or more locations,
typically retail locations. Goods may be stored in the warehouse by pallet load or
individually, and goods may be shipped either by uniform pallet, mixed pallet, or
otherwise. To maximize efficiency, goods are often stored in vertical rack based systems,
multiplying the amount of goods that can be stored in a given amount of square footage.
[0003] Some systems, sometimes known as high density or ultra-high density rack systems,
store pallets of goods in a large, multi-layer rack. Pallets are stored according
to known identifiers such as SKU numbers or the like and kept track of by a computer-based
system. As pallets of goods are stored in the system, the related identifiers are
noted and stored in a computer memory or the like so that when the goods are desired,
they can be retrieved.
[0004] Automated systems of this type use carts that place the goods in the rack and retrieve
the goods when desired. Such automated systems provide efficiency in terms of floor
space usage, as well as quick loading and retrieval of goods with low need for manual
attention or monitoring. Various cart-based rack systems have been proposed, with
one or more carts that travel from a staging area to a storage area to place and retrieve
goods. Existing cart-based systems and related rack structures provide acceptable
storage capabilities. However, as rack systems become larger, improvement in cart
functionality and efficiency, as well as in rack design to handle larger systems,
would be welcome.
[0005] EP-2287093 relates to a racking system and method.
[0006] Aspects and advantages of the invention will be set forth in part in the following
description, or may be apparent from the description, or may be learned through practice
of the invention.
[0007] According to an aspect of the invention there is provided a system for storing and
retrieving items comprising: a rack including a plurality of layers, each layer including
an aisle and a plurality of rows extending from the aisle, the items being storable
in storage locations along the rows, each aisle having a loading position at one end
and transfer positions located along the aisle adjacent ends of the rows; a shuttle
on each layer, at least one of the shuttles being a dual shuttle including a first
cart movable along the aisle between the loading position and the transfer positions,
the dual shuttle including a second cart configured to be carried by the first cart
between the loading position and the transfer positions, the second cart movable in
either direction between a transfer position and a storage location along a row while
carrying an item; and a conveyor located on the dual shuttle operable when the first
cart is at the loading position to move the item onto or off the first cart, wherein
the second cart has a raisable top platform, a first motor for moving the second cart
along the rows and a second motor for selectively raising the top platform to lift
an item, and wherein the top platform is raised by a camming device that rotates around
a horizontal axis. Various options and modifications are possible within the scope
of the appended claims.
[0008] These and other features, aspects and advantages of the present invention will become
better understood with reference to the following description and appended claims.
The accompanying drawings, which are incorporated in and constitute a part of this
specification, illustrate embodiments of the invention and, together with the description,
serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A full and enabling disclosure of the present invention is set forth in the specification,
which makes reference to the appended figures, in which:
Fig. 1 shows a perspective view of a rack system according to certain aspects of the
disclosure;
Fig. 2 shows a side view of the rack system of Fig. 1;
Fig. 3 shows a closeup of a portion of the rack system as in Fig. 2;
Fig. 4 shows an end view of the rack system of Fig. 1;
Fig. 5 shows a closeup of a portion of the rack system as in Fig. 4;
Fig. 6 shows a perspective view of a portion of the rack system of Fig. 1 showing
a bracket portion;
Fig. 7 shows an exploded perspective view of the elements in Fig. 6;
Fig. 8 shows a perspective view of a dual shuttle useful in the rack system of Fig.
1;
Fig. 9 shows a perspective view of a first (aisle) cart of the dual shuttle with a
second (row) cart removed;
Fig. 10 shows a closeup perspective view of a portion of the aisle cart showing a
chain conveyor;
Fig. 11 shows a perspective view of the aisle cart with top housing elements removed
for clarity to show internal drive elements;
Fig. 12 shows a perspective view of a row cart according to certain aspects of the
disclosure;
Fig. 13 shows a perspective view of the row cart of Fig. 12 with its top platform
removed to display internal elements;
Fig. 14 shows a top view of the row cart of Fig. 12 with the top removed;
Fig. 15 shows a top view as in Fig. 14 with lifting bars further removed;
Fig. 16 shows a side diagrammatical view of the row cart of Fig. 12 showing the top
platform in a raised orientation;
Fig. 17 shows a side diagrammatical view as in Fig. 16, with the top platform in a
lowered orientation;
Figs. 18 - 22 show sequential schematic views of a pallet loading function using a
rack system as in Fig. 1 and a dual shuttle as in Fig. 8;
Fig. 23 shows a perspective view of a portion of an aisle cart showing electrical
contacts for powering the aisle cart;
Fig. 24 shows a perspective view of the portion of the aisle cart of Fig. 23 contacting
an electrified rail;
Fig. 25 shows a perspective view of an aisle cart showing electrical contacts for
powering a row cart; and
Fig. 26 shows a perspective view of a bottom portion of a row cart showing electrical
contacts for receiving power from the electrical contacts on the aisle cart shown
in Fig. 25.
DETAILED DESCRIPTION
[0010] Reference now will be made in detail to embodiments of the invention, one or more
examples of which are illustrated in the drawings. Each example is provided by way
of explanation of the invention, not limitation of the invention. In fact, it will
be apparent to those skilled in the art that various modifications and variations
can be made in the present invention without departing from the scope or spirit of
the invention. For instance, features illustrated or described as part of one embodiment
can be used with another embodiment to yield a still further embodiment. Thus, it
is intended that the present invention covers such modifications and variations as
come within the scope of the appended claims and their equivalents.
[0011] Figs. 1-7 show an example of a rack 50 according to certain aspects of the disclosure.
It should be understood that rack 50 as illustrated is but one example constructed
using the present teachings. For example, rack 50 could be much larger than that shown.
Also, multiple racks could be employed in a given location. Therefore, rack 50 could
be a component of a larger combined automated storage system. For example, Figs. 18-22,
discussed below with reference to use of the disclosed structures, shows two side
by side racks 50 substantially larger than that illustrated in Fig. 1. Figs. 20 and
21 also show related equipment such as lifts and conveyors that will also be discussed
below as part of an overall automated system. Therefore, it should be understood that
the full scope of the invention includes all such modifications, extensions and variations.
[0012] As shown in Figs. 1-7, rack 50 includes a plurality of upright elements 52 arranged
in a grid, a plurality of first horizontal elements 54 extending in a first direction
to connect adjacent upright elements, and a plurality of second horizontal elements
56 extending in a second direction perpendicular to the first direction. Rack 50 includes
a number of layers 58 formed by such intersecting horizontal elements 54 and 56. Struts
60 may also be provided to stiffen the structure.
[0013] The upright elements 52 and horizontal elements 54 and 56 are connected via fasteners
attached ultimately to a plurality of support brackets 62. Each upright element 52
has a plurality of support brackets 62 mounted to it at different heights with each
height corresponding to a layer 58. Support brackets 62 are attached to upright elements
52 by fasteners 64 without welding (see Fig. 7). Also, mating tabs 66 and slots 68
may be provided for additional alignment and support assistance both during assembly
and use.
[0014] Each second horizontal element 56 forms one side of a portion of a track for a row
88 to be travelled by a row cart 104, as will be described later. Accordingly, opposing
elements 56 mounted to adjacent brackets 62 form such a row track (see Fig. 3). Second
horizontal elements 56 are attached to brackets 62 via fasteners 70 without welding
(see Fig. 7). Brackets 62 may have flanges 72,74,76 for rigidity and for aligning
and attaching second horizontal elements 56, and flange 77 for aligning and attaching
to upright elements 52.
[0015] First horizontal elements 54 provide spacing and support for elements within rack
50 and may be attached to upright elements 52 with fasteners 78 and to flange 79 of
brackets 62 with additional fasteners 80. End brackets 82 at ends of rack 50 can be
modified versions of brackets 62, designed to accept only one track element 56, if
desired. Again, no welding is required. When goods are stored in rack 50, the goods
are stored in discrete predetermined locations on rows 88 formed by second horizontal
elements 56. Due to the fastened-together structure of rack 50, the weight of the
rack and the stored items is transferred to and supported by upright elements 52 substantially
via brackets 62. Each of the above elements can be formed of a metal such as steel
or aluminum, can be painted, powder coated, etc. as desired. Due to the wide variation
in potential sizes and loading, one skilled in the art can readily select dimensions
and materials for the elements and fasteners to meet a given application need.
[0016] Typically, items to be placed on rack 50 will be moved to and within the rack on
a platform 84 such as a wood, polymer, or metal pallet, although other platforms could
be used, and platforms could be avoided where large or unitized items are being moved.
Accordingly, mention of moving loads, pallet loads, items or goods herein is intended
to include moving items or goods on platforms or without platforms.
[0017] Items are moved within rack 50 in each layer along an aisle 86 and then along one
of the rows 88. Various shuttle devices can be used for such movement into and out
of the rack according to certain aspects of the disclosure (see aisle carts 102 and
row carts 104 in Figs. 2-5, discussed in greater detail below). Along aisle 86, horizontal
elements 54 may be replaced with or supplemented by track elements 90 to transfer
the shuttle device along the aisle. As discussed below, power can be provided to the
shuttle carts 102 and 104 in various locations in the rack.
[0018] Fig. 8 shows one example of a dual shuttle 100 useful in the present system and methods.
As shown, dual shuttle 100 includes a first (aisle) cart 102 (Figs 8-11) and a second
(row) cart 104 (Fig. 8 and 12-17) that can be carried on or driven off the aisle cart.
Track portions 106 on aisle cart 102 are sized to complement track sections 56 of
rack 50 allowing row cart 104 to drive on or off the aisle cart.
[0019] Aisle cart 102 includes two motors 108 and 110. Motor 108 drives aisle cart 102 up
and down track elements 90 of the respective aisle 86 in which the cart is located.
Motor 110 drives a conveyor 112 on aisle cart 102 for loading and unloading items
onto the aisle cart. It should be understood that conveyor 112 could also be located
on row cart, if desired. Also, it should be understood that conveyor 112 can place
items directly onto aisle cart 102, or can place items on row cart 104 nested within
the aisle cart, both of such modes being considered moving the items onto the aisle
cart and/or moving the items onto the dual shuttle. Accordingly, as discussed in greater
detail below, various configurations and modes of operation are possible within the
scope of the present invention.
[0020] Both motors 108,110 can be powered by an energy storage device such as a battery,
capacitor, a combination of a battery and capacitor, or the like charged by suitable
electrical connections (see Figs. 23-26) in rack 50. If desired, even though an energy
storage device that would output DC current could be employed, motors 108,110 can
be AC motors, used with an inverter. Use of such AC motors with an inverter may provide
a less expensive alternative than use of a DC motor.
[0021] Also, as discussed below, aisle cart 102 can receive three-wire single phase or three-phase
AC power directly from track elements 90 via an electrified rail/wiper system. Use
of such direct powering allows aisle cart 102 to be constantly and fully electrified,
without need for charging. Also, the weight and space used by the energy storage devices,
inverter, etc., can be eliminated from each aisle cart 102. Because aisle carts 102
each traverse only one dedicated aisle 86, electrifying the aisles with a track (see
Figs. 23-26) and wiper contact interface is a cost effective solution for powering
aisle carts 102.
[0022] Motor 108 is connected to a gear box 114 with an output gear 116 that drives a chain
118 that drives an input gear 120 of a shaft 122. Wheels 124 are mounted to shaft
122. Wheels 126 mounted on shaft 128 may be idlers. By operating motor 108 in one
way or the other, wheels 124 are rotated clockwise or counterclockwise, thereby moving
aisle cart 102 up and down an aisle in the rack. If desired an encoder or the like
may be attached to one of the wheels, shaft, motor, gearbox, etc., to provide feedback
and control as to location of cart 102 along the aisle. Alternatively or in addition,
external detection devices such as optical or laser detectors, rfid elements, etc.,
may be used for position sensing and control. Cart 102 may include a wireless communication
device (not shown) for communicating with a controller for the system to receive signals
and provide feedback as to desired tasks, locations, etc.
[0023] Motor 110 is connected to a gearbox 129 having a drive gear 130 that drives a chain
132. An input gear 134 of shaft 136 is rotated by chain 132. Two output gears 138
on shaft 136 drive chains 140 of loading/unloading conveyor 112. Accordingly, driving
motor 110 one way or the other causes chains 140 to move one way or another. Such
motion of chains 140 can be used to pull items onto or push items off aisle cart 102
when desired. As shown in Fig. 8, when row cart 104 is nested within aisle cart 102
with its top surface 142 in a retracted (not raised) position, chains 140 are higher
than the top surface. Therefore, movement of chains 140 of loading conveyor 112 with
row cart 104 in place allows a load, pallet, etc., to be moved onto aisle cart 102
without interference by row cart 104. However, carts 102 and 104 could be configured
or operated differently, so that chains 140 move a load onto cart 104, either initially
or after lifting top surface 142 of cart 104, as discussed below. Therefore, although
the description herein shows pallets 84 being supported on chains 140 located on aisle
carts 102, the pallets could at times be supported by row carts 104 when the row carts
are on aisle carts.
[0024] An example of a row cart 104 is shown in Figs. 12-17. Row cart 104 includes a frame
144 and movable top surface 142 forming a platform for receiving loads. Within frame
144 are two motors. Motor 146 drives cart 104 along rows 88 and motor 148 moves top
surface 142 up and down. Motor 146 drives a gearbox 150, an output gear 152 and a
chain 154. Chain 154 drives an input gear 156 of shaft 158 on which driven wheels
160 are mounted. Output gears 162 drive chains 164 that drive input gears 166 of shafts
168 to drive driven wheels 170. Accordingly, driving motor 146 in one direction or
another rotates wheels 160 and 170 clockwise or counterclockwise, thereby moving row
cart 104 along a row 88, or onto or off aisle cart 102.
[0025] Motor 148 lifts top surface 142 off cart 104 when desired to lift an item off either
loading conveyor 112 of cart 102 or a position within storage rack 50. Motor 148 drives
a gearbox 172 and an output gear 174 to drive a chain 176. Chain 176 drives input
gear 178 mounted to shaft 180, to which camming elements 182 are attached for rotation
with shaft 180 around a substantially horizontal axis. Wheels 184 are idlers that
move independently of shaft 180. Camming elements 182 include lifters 186 which may
be in the form of a wheel or the like. Pins 188 and bars 190 connect camming elements
182 with similar camming elements 192 at the other end of frame 144. If desired, a
track element 194 (see Fig. 14, removed in Fig. 15 for clarity) may extend between
camming elements for attachment to or contact with surface 142 when lifters 186 are
activated. Wheels 196 are idlers and an encoder 198 may be attached for rotation with
one of the wheels 196 or elsewhere to track position, as discussed above. Use of eight
wheels on each row cart 104 assists in keeping the row cart stable when driving between
row cart 102 and a row 88.
[0026] Figs. 16 and 17 show schematically the lifting of top surface 142 off frame 144 of
row cart 104. As shown, rotation of motor 148 a small distance causes chain 176 to
move camming elements 182 and camming elements 192 (via bars 190). Accordingly, wheels
186 are moved so as to raise or lower top surface 142 via track elements 194. Fig.
17 shows the top surface 142 below the raised level 200, which is higher than the
level 202 of loading conveyors 112 on aisle cart 102 when the carts 102 and 104 are
nested, and higher than the level of track portions 56 on which loads are placed.
[0027] It should be understood that the gears, chains, etc., used to drive the various components
in carts 102 and 104 could be modified in various ways. For example, multiple motors
could be used instead of connecting multiple driven items by chains and gears. Therefore,
the driving and lifting functions of the carts could be achieved in various ways within
the scope of the invention.
[0028] Cart 104 may be driven via an energy storage device 204 such as batteries, capacitors,
combinations or batteries and capacitors, or the like. Motors 146, 148 may be DC motors
or may be AC motors if an inverter 206 and frequency converter 208 is used (all schematically
shown in Fig. 14). For example, running a battery at 24 VDC through an inverter to
create 230VAC and a frequency converter to allow use of common 400VAC motors can provide
cost and maintenance savings. Batteries rated in the range of 24 Amp-hours provide
suitable power to travel along rows 88 with loads with the duration of charging provided
by contact with aisle cart 102, as described below. If energy storage device 204 includes
a capacitor, it may be an ultra-capacitor providing a substantially equivalent output.
Capacitors provide the benefit of quick charging of row cart 104, as described below,
and accordingly can provide for alternate modes of operation.
[0029] Power can be provided to the dual shuttle 100 in various ways. For example, an electrified
rail may be added along aisles 86 within rack 50 to constantly power aisle cart 102
or charge the energy storage device of the aisle cart, if desired. Since there are
many fewer aisles 86 than rows 88, adding electrification to aisles only can be cost
effective in some applications. Alternatively, charging could be provided at only
one location or some locations along aisles. Such structure would require an energy
storage device within aisle cart 102.
[0030] Similarly, row cart 104 can be charged via an electrified rail or via charge from
a given location. If desired, aisle cart 102 and row cart 104 may have electrical
contacts so that aisle cart can maintain charge on the row cart. As there are many
more rows 88 than aisles 86, adding rail/wiper electrification to all of the rows
while simplifying the row carts 104 so as to eliminate the energy storage device and
related electronics may not be as cost effective as employing more electrically complicated
row carts (with batteries or capacitors, for example) charged via aisle carts 102.
However, if capacitors are used in row carts 104, placing a single charge contact
located at an end of a row adjacent the aisle may be a suitable mode of charging the
row carts. Capacitor charging occurs in a matter of seconds, and each time a row cart
104 passes the end of a row, it could pause just long enough for charging before or
after moving onto or off the aisle cart 102, or charging could occur while the row
cart is idle and the aisle cart is elsewhere. Alternatively, the capacitor charging
contact in the row could be lengthy enough to charge row cart 104 while moving (without
pausing) to make the system more efficient in terms of load moves per hour. Electrically
connecting the carts 102 and 104 so that row carts 104 are charged by aisle carts
102, and aisle carts are charged via an electrified rail, may be the most cost effective
solution in some applications, particularly those with battery powered row carts.
However, it should be understood that various methods and systems of electrical delivery
and usage are possible within the present invention.
[0031] Figs. 18-22 show diagrammatically a large system, using two individual racks 300,
much larger than rack 50, arranged side by side with a number of pieces of auxiliary
equipment. For clarity, certain structure of the previous figures has been eliminated
from Figs. 18-22 so as to focus on overall layout and function.
[0032] As shown, racks 300 each include two lifts 302, one on either side of an aisle 303.
Use of two lifts 302, particularly in a large system, optionally allows greater throughput.
Each lift 302 includes a lift platform 304 onto which items 306 are placed, as illustrated
goods/items 308 on pallets 310. Each lift platform 304 is moved up and down rack 300
along a frame 312 between layers 314 (in this case six, layers).
[0033] A system 316 of feed and delivery conveyors can be provided adjacent lifts 302 and
racks 300. As shown, first conveyors 318 adjacent lifts 302 fed by second conveyors
320 can transfer items to and from the lift platforms 304. An array of third conveyors
322 can be provided along with a common conveyor 324. Third conveyors 322 can be used
with individual vehicles, for example, for loading and unloading. Common conveyor
324 can use a transfer cart 326 similar to aisle cart 102 for receiving items from
one of the third conveyors 322 and distributing it to one of the second conveyors
322 (or vice versa). The various conveyors disclosed can be driven or idler rollers,
belt conveyors, chain conveyors, etc., as desired, with appropriate motor drives,
in various possible orientations and arrangements. The logic and decision making for
storage and retrieval of items in racks 300 can be controlled by various types of
systems available from various sources, including ITW Warehouse Automation, using
programmable logic controllers or the like. Accordingly, it should be understood that
various different systems 316 for feed and delivery of items, as well as logic and
management of items are all within the scope of the present invention.
[0034] Preferably, lift platforms 304 each include a motor driven conveyor 328 with at least
one chain or belt similar to conveyor 112 on shuttle carts 100. Lift conveyors 328
can be used to move items onto or off lift platforms 304 when desired. If some spacing
exists between lifts 302 and aisles 303, that can be taken up by a buffer conveyor
330. Each buffer conveyor 330 can also have one or more motor-driven conveyors 331
such as a chain, belt or the like, however the buffer conveyors could be idlers between
the driven lift platform conveyors 328 and the aisles where shuttles 100 are located.
If desired, all of the lift platforms 304, buffer conveyors 330 and shuttles 100 (aisle
carts 102 and/or row carts 104) may include driven chain or belt conveyors on top
surfaces for selectively moving items. Accordingly, a lift 302 can place an item on
a buffer conveyor 330 in an upper layer when aisle cart 102 is not in a loading position
at the end of aisle 303 next to the buffer conveyor, and then the lift can return
to the base layer to retrieve another item while the aisle cart returns to retrieve
the placed item. Multiple items can be located on a given buffer conveyor 330 while
the dual shuttle carts 102/104 do their work placing other items, or while waiting
for the lift 302 to return to pick them up to deliver them out of rack 300. If buffer
conveyor 330 is used and is also motorized, when aisle cart 102 returns to the loading
position, buffer conveyor 330 and aisle cart conveyor 112 can be activated simultaneously
to pull the item onto the aisle cart. By loading aisle cart 102 using an onboard conveyor
112, row cart 104 need not be sent off and back on the aisle cart for loading, which
saves time and energy within the row cart's batteries. Use of and/or motorizing buffer
conveyor 330 further assists in this efficiency but is not required in all applications.
[0035] For example, in some conventional applications without an onboard conveyor such as
conveyor 112 where a row cart leaves an aisle cart at a loading position of a rack
system adjacent a lift or the like, an amount of time in the range of about 22-25
seconds is required to move a load from the lift to the aisle cart. In this time,
the row cart must start moving off the aisle cart, accelerate, travel, decelerate,
stop moving at the lift, pick up a load, start moving off the lift, accelerate, travel,
decelerate, stop moving at the aisle cart, and then lower the load into the aisle
cart. The time used by such activity impacts the number of pallet moves per hour.
In some large rack systems with 1000-1500 items stored in approximately 50 sets of
rows along an aisle, shuttle systems that load aisle carts using row carts as above
make in the range of 20-25 pallet moves per hour. Such aisle cart loading activity
also causes the row cart to be off the aisle cart twice per each pallet move (receiving
the pallet and depositing the pallet), thereby using more energy per pallet move,
causing a larger, heavier battery to be needed, due to both more activity and less
opportunity for charging per pallet move.
[0036] Using the disclosed shuttle 100 with the loading/unloading conveyor 112 located on
one of carts 102,104, the time needed to load a pallet at a loading position adjacent
a lift in a system of the above size is reduced to the range of less than about 15
seconds and may be in the range of about 5-7 seconds. Therefore, if 15-20 seconds
are saved per pallet move using the disclosed shuttle 100 with loading/unloading conveyor
112, several more pallet moves per hour are possible rendering the entire system more
efficient and/or allowing the size of the rack serviced by a shuttle to be enlarged.
[0037] Efficiency in terms of pallet moves per hour can also be achieved by driving carts
102 and 104 faster than in conventional systems, of course within limits so as to
not mishandle loads. For example, driving row carts 104 at a speed in the range of
4.0 m/s vs. a speed of 2.25 m/s as in certain available systems provides further pallet
move per hour improvement. Acceleration and deceleration can be increased as well
to the range of 0.5 m/s
2 from 0.17 m/s
2 as in certain available systems.
[0038] Accordingly, for a rack system sized as above (1000-1500 items per layer in 50 sets
of rows along an aisle), pallet moves can be increased to a range of above 30 pallet
moves per hour, and further to a range of 40-45 or greater pallet moves per hour,
through use of the onboard loading/unloading conveyor 112 and driving row carts 104
and/or aisle carts 102 faster. Therefore, pallet moves per hour for a given size rack
can be more or less doubled using the various teachings of the present disclosure.
[0039] Further, simultaneous separate operation of row and aisle carts at least some of
the time can help achieve some additional efficiency benefits. For example, if row
carts 104 are not located on aisle carts 102 for charging while the aisle carts return
from a row to the loading/unloading area with a load (or to get a load), the row carts
can be active simultaneously in a row to get or return a load. Simultaneous separate
operation of row and aisle carts therefore can provide even further efficiency benefits
or as many as 60 pallet moves per hour or more, when used with the above improvements
as well. Such simultaneous operation may be achieved by allowing row carts 104 to
be charged sometimes or always off aisle carts 102, for example in rows. Alternatively,
such simultaneous operation could occur on a more limited basis if even if charging
is done only on aisle carts 102. It should be understood that not all aspects of the
disclosure need be used or used to the extent mentioned above in all applications
within the scope of the invention. Further, improvement in function, stability, operation,
etc., does not require an improvement in pallet moves per hour in all aspects of the
invention.
[0040] Figs. 18-21 show the use of lifts 302 and buffer conveyors 330 to get items onto
dual shuttles 100 (including nested carts 102 and 104) at the loading position. Fig.
22 shows that dual shuttle 100 has traveled down an aisle 303 to a desired row 332.
Row cart 104 has raised its upper surface 142 to lift the item off conveyors 112 of
aisle cart 102 and has left the aisle cart to deliver the item to a desired location
in the row 332. Aisle cart 102 may wait for row cart 104 or may return to the lift
area for another load while the row cart operates. After reaching the desired location,
row cart 104 will lower its upper surface 142 to place the item. Row cart 104 may
then return down the row to nest within aisle cart 102, if the aisle cart is waiting
for the row cart, or to wait for the aisle cart to return. Aisle cart 102 will then
either move down aisle 303 to a different row to retrieve an item from storage, sending
row cart 104 out to do so, or return to the loading area at the end of the aisle to
obtain an additional item to place into storage, or allow row cart 104 to take a load
to the present row or a different row if the aisle cart had left to get another load
while the row cart was operating. These patterns repeat as controlled by the master
controller of the entire automated warehousing system, as desired.
[0041] The retrieval of items from the rack is essentially the same pattern in reverse.
Row cart 104 gets a load, carries it to the aisle cart 102, and the two carts return
nested to the loading/unloading position at the end of the aisle. At that point, conveyor
112 drives the load off the shuttle 100.
[0042] As stated, to achieve greater pallet move per hour efficiency, carts 102 and 104
need not always be nested when aisle cart 102 moves between to the rows and the loading/unloading
position at the ends of the aisles. Therefore, during a storing operation, as soon
as row cart 104 leaves aisle cart 102 with a load, the aisle cart could return to
the loading area to get another load. Aisle cart 102 could then return to retrieve
row cart 104, which would drive onto the aisle cart beneath the second load. If the
second load is to be placed in the same row, row cart 104 could place the load in
the row, and the process could repeat. Similar function can occur during retrieval,
as aisle cart 102 can be moving a retrieved load down the aisle to the loading/unloading
position while row cart 104 is moving along a row to get the next load, either in
the same row as previously or a different row (as dropped off by the aisle cart).
[0043] However, operation of the row cart and aisle carts separately in such fashion reduces
the nested time of the row cart on the aisle cart. If row cart 104 is to be powered
and charged by contact only with aisle cart 102, only a limited, defined amount of
usage time off the aisle cart is advisable before the energy storage device in row
cart 104 would be drained. The overall control system can optionally monitor and control
such operation if needed to limit such operation in various ways, such as to allow
only a certain number of row cart trips per hour, to require a certain amount of nested
time per hour, to allow for only a certain number of successive row trips or row trips
only a certain distance from the loading area or from each other, etc. Such limitations
might not be needed if row carts 104 are charged or powered by wiping contact with
electrified rails on rows or other method apart from nesting on aisle carts 102. Row
carts 104 can operate more independently from aisle carts 102 if they have a capacitor
or ultra-capacitor based energy storage device, as such can be charged quickly by
charging pads in the rows, either instead of or in addition to charging on the aisle
carts.
[0044] Figs. 23-26 show one example of electrical connections that could be used to power
the aisle and row carts. As shown, aisle cart 102 can include an electrical contact
400 in the form of a brush, wiper, etc., for receiving power from an electrified track
402 on the side elements 90 forming part of the aisle cart track. As shown, brush
400 has four contacts 404, 406, 408, 410, that can be used to contact individual elements
412, 414, 416, 418 on track 402 for three-phase power AC supply plus ground. If desired,
single-phase AC power could also be provided with positive/negative connections plus
ground. Using a sliding connection in this fashion may be simpler than providing a
cable connection to aisle cart 102 in some applications, although that could also
be employed as an option.
[0045] A contact 420 on top of aisle cart 102 includes two spring-loaded elements 422, 424
for contacting two plates 426, 428 on an electrical connector portion 430 of row cart
104. The storage element (battery and/or capacitor) on row cart 104 can be charged
whenever it is located on aisle cart 102 via contact between elements 422, 424 and
plates 426,428. The location of elements 422,424 and plates 426,428 can be reversed
between the carts. Alternatively, instead of placing elements 422, 424 (or 426,428)
on aisle cart 102, such elements could be placed in the rack, for example in the center
of the end of each row adjacent the aisle. Such location could be particularly useful
if capacitors or ultra-capacitors are employed as an energy storage device within
carts 104. As a further alternative, row carts 104 could employ a wiper and track
system as disclosed for aisle carts 102 above for direct powering or charging or an
energy storage device. Various devices suitable for making the electrical connections
between the aisle cart track 90 and aisle cart 102, and between the aisle cart and
row cart 104 or rack, are available from Vahle Electrification Systems.
[0046] Use of such power delivery systems allowing the row carts 104 to be charged on the
aisle carts 102 and/or within rack, while also driving the row carts off the aisle
carts to go up and down rows and not to have to load or unload at the loading locations
at the lift platforms 304, provides various benefits. First, the system can move more
loads per hour, as using the lift conveyor 328 and optional buffer conveyor 331 chains
to move loads between the lifts and dual shuttle is generally faster than driving
the row cart 104 back and forth off the aisle cart 102 to do so. Also, keeping the
row cart 104 on the aisle cart 102 for more time provides more time within a duty
cycle for charging and/or allows for use of a smaller storage device in the row cart,
thereby potentially providing cost savings for the storage device and the motor used
to drive it. However, within certain aspects of the invention even if a row cart 104
is driven off an aisle cart 102 to load and unload items at a loading/unloading position
the end of the aisle, other disclosed structures and methods above provide other benefits
within the scope of the present invention.
[0047] In view of the above, a rack, a dual shuttle, an aisle cart, a row cart, and an automated
warehousing system are disclosed having various benefits. Further, methods of use
of such items are disclosed. The systems may allow for a more rapid storage and retrieval
of items, may employ smaller and more efficient carts, and may be easier to assemble
and use. Numerous benefits are provided by the various disclosed subject matter curing
at least some of the drawbacks posed by conventional systems.
[0048] This written description uses examples to disclose the invention, including the best
mode, and also to enable any person skilled in the art to practice the invention,
including making and using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the claims, and may include
other examples that occur to those skilled in the art. Such other examples are intended
to be within the scope of the claims if they include structural elements that do not
differ from the literal language of the claims, or if they include equivalent structural
elements with insubstantial differences from the literal languages of the claims.
1. A system for storing and retrieving items comprising:
a rack (50;300) including a plurality of layers, each layer including an aisle (86;303)
and a plurality of rows (88) extending from the aisle (86,303), the items being storable
in storage locations along the rows (88), each aisle (86,303) having a loading position
at one end and transfer positions located along the aisle (86,303) adjacent ends of
the rows (88);
a shuttle (100) on each layer, at least one of the shuttles (100) being a dual shuttle
including a first cart (102) movable along the aisle (86,303) between the loading
position and the transfer positions, the dual shuttle including a second cart (104)
configured to be carried by the first cart (102) between the loading position and
the transfer positions, the second cart (104) movable in either direction between
a transfer position and a storage location along a row (88) while carrying an item;
and
a conveyor (112) located on the dual shuttle operable when the first cart (102) is
at the loading position to move the item onto or off the first cart (102),
wherein the second cart (104) has a raisable top platform (142), a first motor (146)
for moving the second cart (104) along the rows (88) and a second motor (148) for
selectively raising the top platform (142) to lift an item,
and wherein the top platform (142) is raised by a camming device (182,186,192) that
rotates around a horizontal axis.
2. The system of claim 1, wherein the conveyor (112) is on the first cart (102).
3. The system of one of the above claims, wherein the second cart (104) is located on
the first cart (102) when the conveyor (112) is operated.
4. The system of one of the above claims, wherein the conveyor (112) moves the item directly
onto the first cart (102).
5. The system of one of the above claims, including a lift (302) substantially adjacent
the rack (50;300) for lifting items to the respective loading positions for the layers.
6. The system of claim 5, wherein the lift includes a platform (304) having a conveyor
(328) for moving items off the lift platform (304) and toward the loading positions
of the respective layers.
7. The system of claim 6, wherein each layer of the rack (50;300) includes a conveyor
(330,331) adjacent the loading position for transferring items from the lift platform
(304) to the loading position.
8. The system of one of the above claims, wherein the first cart (102) has a first motor
(108) for moving the first cart (102) along the aisle (86;303) and a second motor
(110) for driving the conveyor (112).
9. The system of claim 8, wherein the first and second motors (108,110) of the first
cart (102) are AC motors.
10. The system of one of the above claims, wherein the top platform (142) can be lifted
to remove an item from the first cart (102) when the first and second carts (102,104)
are located at a transfer position so that the second cart (104) can carry the item
to a storage location in the respective row (88).
11. The system of one of the above claims, wherein the top platform (142) can be lifted
to retrieve an item from a storage location in a row (88) so that the second cart
(104) can carry the item to the first cart (102), the first cart (102) then carrying
the item to the loading position for transfer out of the rack (50;300).
12. The system of one of the above claims, wherein the first and second motors (146,148)
of the second cart (104) are AC motors.
13. The system of one of the above claims, wherein the second cart (104) has an energy
storage device (204) for storing energy used to power the second cart (104), preferably
wherein the energy storage device (204) in the second cart (104) is a charged via
electrical contact between the second cart (104) and the first cart (102)preferably,
wherein the energy storage device (204) in the second cart (104) is charged via electrical
contact between the second cart (104) and the rack (50;300), preferably, wherein the
energy storage device (204) is a battery or a capacitor.
14. The system of one of the above claims, wherein the dual shuttle (100) is powered via
electrical contact between the dual shuttle (100) and the rack (50;300).
15. The system of one of the above claims, wherein the second cart (104) is powered so
as to move along a row (88) while the first cart (102) moves along the aisle (86;303).
1. Anlage zum Lagern und Wiedererlangen von Artikeln, umfassend:
ein Gestell (50; 300) mit einer Vielzahl von Ebenen, wobei jede Ebene eine Spur (86;
303) und eine Vielzahl von Reihen (88) aufweist, die sich von der Spur (86, 303) erstrecken,
wobei die Artikel an Lagerstandorten entlang der Reihen (88) gelagert werden können,
wobei jede Spur (86, 303) eine Ladeposition an einem Ende und Transferpositionen aufweist,
die entlang der benachbarten Enden der Spur (86, 303) der Reihen (88) angeordnet sind;
einen Shuttle (100) auf jeder Ebene, wobei mindestens einer der Shuttles (100) ein
Doppel-Shuttle ist, der einen ersten Wagen (102) aufweist, der entlang der Spur (86,
303) zwischen der Ladeposition und den Transferpositionen beweglich ist, wobei der
Doppel-Shuttle einen zweiten Wagen (104) aufweist, der konfiguriert ist, um von dem
ersten Wagen (102) zwischen der Ladeposition und den Transferpositionen getragen zu
werden, wobei der zweite Wagen (104) in jede Richtung zwischen einer Transferposition
und einem Lagerstandort entlang einer Reihe (88) beweglich ist, während er einen Artikel
trägt; und
einen Förderer (112), der auf dem Doppel-Shuttle angeordnet ist, und betrieben werden
kann, wenn der erste Wagen (102) in der Ladeposition ist, um den Artikel auf den und
vom ersten Wagen (102) zu bewegen,
wobei der zweite Wagen (104) eine anhebbare obere Plattform (142), einen ersten Motor
(146) zum Bewegen des zweiten Wagens (104) entlang der Spuren (88) und einen zweiten
Motor (148) zum selektiven Anheben der oberen Plattform (142) zum Anheben eines Artikels
aufweist
und wobei die obere Plattform (142) von einer Nockenvorrichtung (182, 186, 192) angehoben
wird, die um eine horizontale Achse dreht.
2. Anlage nach Anspruch 1, wobei der Förderer (112) auf dem ersten Wagen (102) ist.
3. Anlage nach einem der vorherigen Ansprüche, wobei der zweite Wagen (104) auf dem ersten
Wagen (102) angeordnet ist, wenn der Förderer (112) betrieben wird.
4. Anlage nach einem der vorherigen Ansprüche, wobei der Förderer (112) den Artikel direkt
auf den ersten Wagen (102) bewegt.
5. Anlage nach einem der vorherigen Ansprüche, aufweisend eines Lift (302), der im Wesentlichen
benachbart zu dem Gestell (50; 300) zum Anheben von Artikeln zu den zugehörigen Ladepositionen
für die Ebenen befindlich ist.
6. Anlage nach Anspruch 5, wobei der Aufzug eine Plattform (304) mit einem Förderer (328)
zum Bewegen von Artikeln von der Hebeplattform (304) und in Richtung der Ladepositionen
der zugehörigen Ebenen aufweist.
7. Anlage nach Anspruch 6, wobei jede Ebene des Gestells (50; 300) einen Förderer (330,
331) neben der Ladeposition zum Übertagen der Artikel von der Hebeplattform (304)
zur Ladeposition aufweist.
8. Anlage nach einem der vorherigen Ansprüche, wobei der erste Wagen (102) einen ersten
Motor (108) zum Bewegen des ersten Wagens (102) entlang der Spur (86; 303) und einen
zweiten Motor (110) zum Antreiben des Förderers (112) aufweist.
9. Anlage nach Anspruch 8, wobei der erste und der zweite Motor (108, 110) des ersten
Wagens (102) Drehstrommotoren sind.
10. Anlage nach einem der vorherigen Ansprüche, wobei die obere Plattform (142) zum Entfernen
eines Artikels aus dem ersten Wagen (102) angehoben werden kann, wenn der erste und
der zweite Wagen (102, 104) an einer Transferposition angeordnet sind, sodass der
zweite Wagen (104) den Artikel zu einem Lagerstandort in der zugehörigen Ebene (88)
tragen kann.
11. Anlage nach einem der vorstehenden Ansprüche, wobei die obere Plattform (142) zum
Wiedererlangen eines Artikels von einem Lagerstandort in einer Reihe (88) angehoben
werden kann, sodass der zweite Wagen (104) den Artikel zu dem ersten Wagen (102) tragen
kann, wobei der erste Wagen (102) dann den Artikel zu der Ladeposition zum Transferieren
aus dem Gestell (50; 300) tragen kann.
12. Anlage nach einem der vorstehenden Ansprüche, wobei der erste und der zweite Motor
(146, 148) des zweiten Wagens (104) Drehstrommotoren sind.
13. Anlage nach einem der vorstehenden Ansprüche, wobei der zweite Wagen (104) eine Energiespeichervorrichtung
(204) zum Speichern von Energie aufweist, die zum Antreiben des zweiten Wagens (104)
verwendet wird, wobei vorzugsweise die Energiespeichervorrichtung (204) in dem zweiten
Wagen (104) über einen elektrischen Kontakt zwischen dem zweiten Wagen (104) und vorzugsweise
dem ersten Wagen (102) aufgeladen wird, wobei die Energiespeichervorrichtung (204)
in dem zweiten Wagen (104) über einen elektrischen Kontakt zwischen dem zweiten Wagen
(104) und vorzugsweise dem Gestell (50; 300) aufgeladen wird, wobei die Energiespeichervorrichtung
(204) eine Batterie oder ein Kondensator ist.
14. Anlage nach einem der vorherigen Ansprüche, wobei der Doppel-Shuttle (100) über einen
elektrischen Kontakt zwischen dem Doppel-Shuttle (100) und dem Gestell (50; 300) betrieben
wird.
15. Anlage nach einem der vorherigen Ansprüche, wobei der zweite Wagen (104) betrieben
wird, um sich entlang einer Reihe (88) zu bewegen, während sich der erste Wagen (102)
entlang der Spur (86; 303) bewegt.
1. Système pour entreposer et récupérer des articles, le système comprenant :
une baie (50 ; 300) comportant une pluralité de couches, chaque couche comportant
un couloir (86 ; 303) et une pluralité de rangées (88) s'étendant depuis le couloir
(86, 303), les articles étant entreposables à des emplacements d'entreposage le long
des rangées (88), chaque couloir (86, 303) comportant une position de chargement à
une extrémité et des positions de transfert situées le long du couloir (86, 303),
adjacentes à des extrémités des rangées (88) ;
une navette (100) sur chaque couche, au moins une des navettes (100) prenant la forme
d'une navette double comportant un premier chariot (102) mobile le long du couloir
(86, 303) entre la position de chargement et les positions de transfert, la navette
double comportant un deuxième chariot (104) configuré pour être porté par le premier
chariot (102) entre la position de chargement et les positions de transfert, le deuxième
chariot (104) étant mobile dans l'une ou l'autre direction entre une position de transfert
et un emplacement d'entreposage le long d'une rangée (88) tandis qu'il porte un article
; et
un transporteur (112) situé sur la navette double, utilisable, lorsque le premier
chariot (102) occupe la position de chargement, pour placer l'article sur le premier
chariot (102) ou l'en retirer,
dans lequel le deuxième chariot (104) est doté d'une plateforme supérieure relevable
(142), d'un premier moteur (146) pour déplacer le deuxième chariot (104) le long des
rangées (88) et d'un deuxième moteur (148) pour relever de façon sélective la plateforme
supérieure (142) afin de soulever un article,
et dans lequel la plateforme supérieure (142) est relevée par un dispositif à effet
de came (182, 186, 192) qui tourne autour d'un axe horizontal.
2. Système selon la revendication 1, dans lequel le transporteur (112) se trouve sur
le premier chariot (102).
3. Système selon l'une des revendications précédentes, dans lequel le deuxième chariot
(104) est situé sur le premier chariot (102) lorsque le transporteur (112) est utilisé.
4. Système selon l'une des revendications précédentes, dans lequel le transporteur (112)
place l'article directement sur le premier chariot (102).
5. Système selon l'une des revendications précédentes, comportant un élévateur (302)
sensiblement adjacent à la baie (50 ; 300) pour soulever des articles jusqu'aux positions
de chargement respectives pour les couches.
6. Système selon la revendication 5, dans lequel l'élévateur comporte une plateforme
(304) dotée d'un transporteur (328) pour enlever des articles de la plateforme (304)
de l'élévateur et les diriger vers les positions de chargement des couches respectives.
7. Système selon la revendication 6, dans lequel chaque couche de la baie (50 ; 300)
comporte un transporteur (330, 331) adjacent à la position de chargement pour transférer
des articles depuis la plateforme (304) de l'élévateur jusqu'à la position de chargement.
8. Système selon l'une des revendications précédentes, dans lequel le premier chariot
(102) est doté d'un premier moteur (108) pour déplacer le premier chariot (102) le
long du couloir (86 ; 303) et d'un deuxième moteur (110) pour entraîner le transporteur
(112).
9. Système selon la revendication 8, dans lequel les premier et deuxième moteurs (108,
110) du premier chariot (102) sont des moteurs à courant alternatif.
10. Système selon l'une des revendications précédentes, dans lequel la plateforme supérieure
(142) peut être soulevée pour retirer un article du premier chariot (102) lorsque
les premier et deuxième chariots (102, 104) occupent une position de transfert en
permettant ainsi au deuxième chariot (104) de porter l'article jusqu'à un emplacement
d'entreposage dans la rangée (88) respective.
11. Système selon l'une des revendications précédentes, dans lequel la plateforme supérieure
(142) peut être soulevée pour récupérer un article depuis un emplacement d'entreposage
dans une rangée (88) en permettant ainsi au deuxième chariot (104) de porter l'article
jusqu'au premier chariot (102), le premier chariot (102) portant ensuite l'article
jusqu'à la position de chargement en vue de son transfert hors de la baie (50 ; 300).
12. Système selon l'une des revendications précédentes, dans lequel les premier et deuxième
moteurs (146, 148) du deuxième chariot (104) sont des moteurs à courant alternatif.
13. Système selon l'une des revendications précédentes, dans lequel le deuxième chariot
(104) est doté d'un dispositif accumulateur d'énergie (204) pour accumuler de l'énergie
servant à alimenter le deuxième chariot (104), de préférence dans lequel le dispositif
accumulateur d'énergie (204) dans le deuxième chariot (104) est chargé par contact
électrique entre le deuxième chariot (104) et le premier chariot (102), de préférence
dans lequel le dispositif accumulateur d'énergie (204) dans le deuxième chariot (104)
est chargé par contact électrique entre le deuxième chariot (104) et la baie (50 ;
300), de préférence dans lequel le dispositif accumulateur d'énergie (204) est une
batterie ou un condensateur.
14. Système selon l'une des revendications précédentes, dans lequel la navette double
(100) est alimentée par contact électrique entre la navette double (100) et la baie
(50 ; 300).
15. Système selon l'une des revendications précédentes, dans lequel le deuxième chariot
(104) est alimenté de façon à se déplacer le long d'une rangée (88) tandis que le
premier chariot (102) se déplace le long du couloir (86 ; 303).